Non-aqueous electrolyte secondary battery

Abstract

A method of fabricating a porous film of a non-aqueous electrolyte secondary battery and a method of fabricating the electrode of a non-aqueous electrolyte secondary battery by which a highly safe and inexpensive non-aqueous electrolyte secondary battery can be produced, and a highly safe and inexpensive non-aqueous electrolyte secondary battery are disclosed. The method of fabricating the electrode of a non-aqueous electrolyte secondary battery according to the invention comprises the steps of forming an electrode plate providing a positive electrode or a negative electrode of a non-aqueous electrolyte secondary battery and forming and attaching a porous film of a polymer material on the surface of the electrode plate thereby to produce the electrode plate having the porous film on the surface thereof. The step of attaching a porous film includes the step of modifying at least a portion of the porous film by bonding a predetermined substituent different from the group contained in the polymer material to the carbon atoms of the backbone chain of the polymer material through two or more successive carbon atoms in the predetermined substituent after the porous film forming step.

What is claimed is:  
     
         1 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, comprising the steps of: 
 forming a porous film composed of a polymer material; and    modifying at least a portion of said porous film by bonding a predetermined substituent different from the group contained in said polymer material to the carbon atoms of the backbone chain of said polymer material through at least two successive carbon atoms in said predetermined substituent.    
     
     
         2 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 1 , 
 wherein said modification step is for causing a modifier having one to 100 parts by mass of said predetermined substituent to react with 100 parts by mass of said polymer material constituting said porous film.    
     
     
         3 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 1 , 
 wherein said porous film forming step is for forming a porous film using a mixture material of said polymer material and said modifier having said predetermined substituent.    
     
     
         4 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 1 , 
 wherein said modification step includes the step of coating said modifier having said predetermined substituent on the surface of said porous film, and    wherein a selected one of said predetermined substituent of said modifier and said backbone chain is bonded to said predetermined substituent after said coating step.    
     
     
         5 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 1 , 
 wherein said modification step includes the step of radiating a high-energy beam on said porous film thereby to bond a selected one of said predetermined substituent and said backbone chain to said predetermined substituent.    
     
     
         6 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 1 , 
 wherein said modification step includes the step of coating an initiator for starting the linkage between selected one of said predetermined substituent and said backbone chain and said predetermined substituent by heating said porous film, and the step of heating said porous film.    
     
     
         7 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to any one of  claims 2  to  6 , 
 wherein said modifier contains at least one compound having at least one polymerization group.  
 
     
     
         8 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 7 , 
 wherein said polymerization group is an unsaturated multiple bond.    
     
     
         9 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to any one of  claims 2  to  6 , 
 wherein said modifier is at least selected one of monoallyl isocyanurate, diallyl isocyanurate, triallyl isocyanurate, triallyl cyanurate, ethylene glycol di-{meth} acrylate, trimethyl propantri {meth}-acrylate, diallyl phthalate, divinyl benzene, vinyl toluene, vinyl pyridine, triallyl phthalate, vinyl trichlorosilane, vinyl tris (β-methoxy ethoxy) silane, vinyl triethoxy silane, vinyl trimethoxy silane, γ-({meth}-acryloxy propyl) trimethoxy silane, γ-({meth} acryloxy propyl) triethoxy silane, γ-({meth}-acryloxy propyl) methyl dimethoxy silane and acryl silicone.  
 
     
     
         10 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 1 , 
 wherein said polymer material is at least one of polybenzoimdazole, polyimide, polyether imide, polyamide imide, polyphenylene sulfide, polyether sulfone, polysulfone, polyether ether ketone, polymethyl pentene, aramide, polyvinylidene fluoride, polyamide, polyethylene telephthalate, polybutylene telephthalate, polyethylene naphthalate, polybutylene naphthalate, polyarylate, polyacetal and polyphenylene ether.    
     
     
         11 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 7 , 
 wherein said modifier is a compound having a LUMO energy value of not less than 0.3 eV with the polymerization group open.    
     
     
         12 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 11 , 
 wherein said modifier includes at least one of ethylene glycol dimethacrylate, trimethyrol propane trimethacrylate, cyclohexyl methacrylate, octafluoro pentyl acrylate, octafluoro pentyl methacrylate, tetrafluoro propyl acrylate, tetrafluoro propyl methacrylate, vinyltris (β-methoxy ethoxy) silane, vinyl triethoxy silane, vinyltrimethoxy silane, γ-(acryloxy propyl) trimethoxy silane, γ-(methacryloxy propyl) trimethoxy silane, γ-(acryloxy propyl) triethoxy silane, and γ-(methacryloxy propyl) triethoxy silane.    
     
     
         13 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 7 , 
 wherein said modifier is a compound having a HOMO energy value of not more than −10.1 eV with the polymerization group open.    
     
     
         14 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 13 , 
 wherein said modifier includes at least one of ethylene glycol dimethacrylate, trimethyrol propane trimethacrylate, cyclohexyl methacrylate, octafluoro pentyl acrylate, octafluoro pentyl methacrylate, tetrafluoro propyl acrylate, tetrafluoro propyl methacrylate, heptadecafluoro decylacrylate, heptadecafluoro decylmethacrylate, vinyltris (β-methoxy ethoxy) silane, vinyl triethoxy silane, vinyltrimethoxy silane, γ-(acryloxy propyl) trimethoxy silane, and γ-(acryloxy propyl) triethoxy silane.    
     
     
         15 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 1 , wherein said predetermined substituent has a —SiOSi— structure.  
     
     
         16 . A method of fabricating a porous film of a non-aqueous electrolyte secondary battery, according to  claim 1 , further comprising the step of bonding said predetermined substituent to a second modifier having a —SiOSi— structure.  
     
     
         17 . A method of fabricating the electrode of a non-aqueous electrolyte secondary battery, comprising the steps of: 
 forming an electrode plate providing a positive electrode or a negative electrode of said non-aqueous electrolyte secondary battery; and    attaching a porous film constituted of a polymer material on the surface of said electrode plate by forming said porous film on said surface of said electrode plate thereby to produce said electrode with a porous film formed thereon;    wherein said porous film attaching step includes the step of modifying at least a portion of said porous film by bonding a predetermined substituent different from the group contained in said polymer material to the carbon atoms of the backbone chain of said polymer material through at least two successive carbon atoms in said predetermined substituent after said porous film forming step.    
     
     
         18 . A method of fabricating the electrodes of a non-aqueous electrolyte secondary battery, according to  claim 17 , 
 wherein said porous film forming step is for forming a porous film on the surface of said electrode plate by coating said polymer material in liquid state on the surface of said electrode plate.    
     
     
         19 . A method of fabricating the electrodes of a non-aqueous electrolyte secondary battery, according to  claim 17 , 
 wherein said porous film forming step is for forming a porous film separate from said electrode plate, and    wherein said porous film attaching step includes the step of securely fixing said porous film on the surface of said electrode plate after said porous film forming step.    
     
     
         20 . A porous film composed of a polymer material for a non-aqueous electrolyte secondary battery, 
 wherein at least a portion of said polymer material is modified by a predetermined substituent different from the group contained in said polymer material, said predetermined substituent having at least two successive carbon atoms bonded to the carbon atoms of the backbone chain of said polymer material.    
     
     
         21 . A porous film of a non-aqueous electrolyte secondary battery, according to  claim 20 , 
 wherein a protective layer induced from the modifier having a LUMO energy value of not less than 0.3 eV is formed on the surface of said porous film with the polymerization group open.    
     
     
         22 . A porous film of a non-aqueous electrolyte secondary battery, according to  claim 21 , 
 wherein said polymerization group is an unsaturated multiple bond.    
     
     
         23 . A porous film of a non-aqueous electrolyte secondary battery, according to  claim 21 , 
 wherein said modifier includes at least one of ethylene glycol dimethacrylate, trimethyrol propane trimethacrylate, cyclohexyl methacrylate, octafluoro pentyl acrylate, octafluoro pentyl methacrylate, tetrafluoro propyl acrylate, tetrafluoro propyl methacrylate, vinyltris (β-methoxy ethoxy) silane, vinyl triethoxy silane, vinyltrimethoxy silane, γ-(acryloxy propyl) trimethoxy silane, γ-(methacryloxy propyl) trimethoxy silane, γ-(acryloxy propyl) triethoxy silane, and γ-(methacryloxy propyl) triethoxy silane    
     
     
         24 . A porous film of a non-aqueous electrolyte secondary battery, according to  claim 20 , 
 wherein a protective layer induced from the modifier having a HOMO energy value of not more than −10.1 eV is formed on the surface of said porous film with the polymerization group open.    
     
     
         25 . A porous film of a non-aqueous electrolyte secondary battery, according to  claim 24 , 
 wherein said polymerization group is an unsaturated multiple bond.    
     
     
         26 . A porous film of a non-aqueous electrolyte secondary battery, according to  claim 24 , 
 wherein said modifier includes at least one of ethylene glycol dimethacrylate, trimethyrol propane trimethacrylate, cyclohexyl methacrylate, octafluoro pentyl acrylate, octafluoro pentyl methacrylate, tetrafluoro propyl acrylate, tetrafluoro propyl methacrylate, heptadecafluoro decylacrylate, heptadecafluoro decylmethacrylate, vinyltris (β-methoxy ethoxy) silane, vinyl triethoxy silane, vinyltrimethoxy silane, γ-(acryloxy propyl) trimethoxy silane, and γ-(acryloxy propyl) triethoxy silane.    
     
     
         27 . A porous film of a non-aqueous electrolyte secondary battery, according to  claim 20 , 
 wherein said predetermined substituent has a —SiOSi— structure.    
     
     
         28 . A porous film of a non-aqueous electrolyte secondary battery, according to  claim 20 , 
 wherein said predetermined substituent is bonded to a second modifier having a —SiOSi— structure.    
     
     
         29 . An electrode of a non-aqueous electrolyte secondary battery, comprising: 
 an electrode plate providing a positive electrode or a negative electrode for the non-aqueous electrolyte secondary battery; and    a porous film configured of a polymer material and integrally formed on said electrode plate with at least selected one of the backbone chain of said polymer material modified by a predetermined substituent different from the group contained in said polymer material.    
     
     
         30 . A non-aqueous electrolyte secondary battery, comprising an electrode unit including a positive electrode and a negative electrode stacked one on the other through a separator, 
 wherein said separator is selected one of the porous film fabricated by the method of fabricating a porous film of non-aqueous electrolyte secondary battery according to any one of  claims 1  to  16  and the porous film of a non-aqueous electrolyte secondary battery according to  claim 20 .    
     
     
         31 . A non-aqueous electrolyte secondary battery, comprising an electrode unit including a positive electrode and a negative electrode stacked one on the other, 
 wherein selected one of said positive electrode and said negative electrode is selected one of the electrode fabricated by the method of fabricating a non-aqueous electrolyte secondary battery according to any one of  claims 17  to  19  and the electrode of a non-aqueous electrolyte secondary battery according to claim  29 .